Saito FA-60T, FA-90TS, FA-100T, FA-182TD, FA-130TD Instruction Manual

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Page 1

TWIN-CYLINDER FOUR-STROKE ENGINES

INSTRUCTION MANUAL

• FA-60T

• FA-90TS

• FA-100T

• FA-130TD

• FA-182TD

• FA-300TL

• FA-300TTDP

Page 2

VERY IMPORTANT

Failure to read and follow these instructions before you proceed may result in engine damage and the voiding of your warranty.

Page 3

SAFETY INSTRUCTIONS

Introduction

Congratulations on purchasing a Saito 4-cycle engine. Cared for properly, these high-quality, finely crafted engines offer many years of modeling enjoyment.

This instruction manual has been developed to ensure optimum performance from the Saito engine you have purchased. The instructions must be read through completely and understood thoroughly prior to mounting and running the engine.

Safety Instructions

This model engine will give you considerable pleasure, satisfaction and performance if you strictly follow these safety instructions and take heed of the warnings as to its safe and proper use. Remember at all times, IT IS NOT A TOY,but a precisionbuilt machine with more than enough power to cause harm if misused, or if the safety precautions are not observed.

You should always:

1. Mount the engine securely on the test bench using the high-quality Saito motor mount supplied. Never clamp the engine in a vice.

2. When running the engine, be sure that all spectators, especially children, are at least 20 feet away.

3. Use the correct size and pitch of propeller for your engine; refer to the propeller chart on page 18 of this manual.

4. It is extremely important to balance the propeller prior to installation. Failure to do so may cause damage to the Saito engine and/or the airframe. Install the propeller with the convex (curved) side facing forward. Securely tighten the propeller nut against the washer and propeller. A “jam” nut is suggested for all 4-cycle engines.

5. Inspect the tightness of the propeller nut prior to each flight.

6. Keep your face and body away from the path of the propeller blades when starting or running your engine.

7. Never allow your hands to come close to the propeller. Use either a “chicken stick” or electric starter to start the engine.

8. Make all carburetor adjustments from behind the propeller.

9. To stop the engine, cut off the fuel supply (pinch or disconnect the fuel line to the carburetor), or use the throttle linkage to shut off the air.

Page 4

SAFETY INSTRUCTIONS

DO NOT USE HANDS, FINGERS OR ANY OTHER PART OF THE BODY TO STOP THE PROPELLER. DO NOT THROW ANY OBJECT INTO A PROPELLER TO STOP IT.

10. Discard any propeller that is nicked, scratched, cracked or damaged in any way.

It is highly recommended that:

1. Safety glasses or goggles be worn when starting and running your engine.

2. You do not run the engine in the vicinity of loose gravel or sand. The propeller may throw such materials into your face and eyes. The engine may also ingest these harmful materials.

3. Loose clothing should be avoided when operating your model engine. Loose clothing may become entangled in the propeller, creating the possibility of bodily harm. Also, all loose objects (screwdrivers, pencils, nickel cadmium starters, etc.) should be removed from your pockets so they do not fall into the propeller.

4. Glow plug clips and cords are kept well away from the propeller.

5. Your glow fuel is kept in a safe place well away from sparks, heat or anything which can ignite the fuel.

Beware:

1. Model engines get very hot while running. Do not attempt to handle them until they have cooled.

2. Always run your model engines in a well-ventilated area. Similar to automotive engines, model engines produce possibly harmful carbon monoxide fumes.

3. Remember that model engines produce a substantial amount of power, more than enough to seriously injure people and/or do considerable damage to property. Always use common sense, skill and constant observation of safety precautions.

Disassembly

Do not needlessly disassemble your Saito engine. Engine repairs should be performed only by qualified individuals. Damage due to improper disassembly will not be covered under the warranty.

Page 5

SUPPORT EQUIPMENT

Engine Parts Identification

It is important to be able to identify the parts of your Saito engines. In the back of this manual you will find an exploded view of Saito twin-cylinder engines, as well as a chart which includes part numbers and descriptions. This will assist you in easily and rapidly identifying the respective parts of your Saito engine.

Support Equipment

The following items, which are not included with your Saito engine, are necessary in order to operate the model engine:

1. Fuel. For maximum protection and longevity of Saito engines, Saito recommends a fuel containing 20% oil and 10–15% nitro methane. If this blend is not readily available, the next best selection is a high quality 2cycle glow fuel, such as Cool Power, K&B, Power Master, etc. Fuels composed entirely of castor oil are not recommended. Use of such fuels will void the warranty.

2. Propeller. Refer to the Propeller Selection Chart, located on page 18, to determine the best initial propeller for your particular application.

3. Glow Plug Battery. Your glow plug may be properly heated by several different sources. The Hangar 9 Po wer Panel (HAN106), when accompanied by a 12V sealed lead acid battery (HAN102) and a glow plug locking socket (HAN120), is an ideal source of heat for your glow plug. A conventional 1.5V hea vy-duty dry cell battery with a glow plug locking socket (HAN120) or alligator clips can also be used. Additionally, there are several very good glo w-starters (nick el cadmium powered glow plug ignitors) which work well.

4. Glow Plug Wrench.A glow plug wrench is used to remove and tighten glow plugs. The Hangar 9 Long Reach Plug Wrench (HAN2510) is an excellent wrench to utilize as a longer shaft may be necessary to access the glow plug. This depends mostly upon engine installation.

5. Manual or Electric Starter. For manual starts, a “chicken stick” is highly recommended. never use your fingers to start any model engine, as doing so invites injury. There are a variety of electric starters on the market. The Hangar 9 12V HeavyDuty Super Starter (HAN110) will work perfectly on all of the twincylinder Saito engines.

Page 6

STARTING THE ENGINE

Break-In

The first run on any engine, whether 2-cycle or 4-cycle, is critical to the future of the engine itself. During this time, metal mating parts (piston and cylinder, ball bearings, etc.) wear in. Care must be taken that the engine is clean and free of any dust or grit that may have accumulated while building the model.

There are two accepted methods for breaking in a new engine: test stand mounted and run or aircraft mounted and run. Either method is acceptable, however, mounting the engine to a test stand allows the engine to be observed throughout its operation, as well as elevating it above the ground and away from harmful dust and dirt.

NOTE: Because your engine may have been sitting for an extended period of time prior to running it, a few drops of light oil applied through the crankcase breather nipple (19 on the exploded view),if applicable,and down the pushrod tubes (40) will ensure proper lubrication for the first run.

Regardless of the mounting method chosen for break-in, the following procedures are applicable:

1. Use a break-in fuel as described in the “Support Equipment” Section on page 3 of this manual.

2. Use the proper glow plugs. Your engine includes the Hangar 9/McCoy MC-4C (HAN3010) glow plugs, which are also the standard replacement glow plugs for these engines.

3. Select the correct propeller. To do so, refer to the Propeller Selection Chart on page 18 of this manual.

4. Make sure that the high speed needle valve(s) (85) are opened (turned counterclockwise) five full turns. This guarantees a very rich setting.

Do not adjust the low-speed needle valve(s) or airbleed screws (89) at this time. The low speed needle valve(s), or airbleed screws, are preadjusted at the factory for initial break-in.

5. The use of a tachometer is highly recommended since the adjustment of a 4-cycle engine, while similar to that of a 2-cycle engine, is more difficult to “set by ear,”therefore making it easier to damage the engine by “over leaning.”

Page 7

STARTING THE ENGINE

Starting The Engine

1. Make sure the glow plugs are installed and tightened.

2. Be sure the propeller is properly secured. The use of a “jam nut” is encouraged on 4-cycle engines.

3. Make sure the fuel tank line(s) are properly connected. The main line should be connected to the carburetor spray bar (84).

NOTE: If your Saito engine is equipped with dual carburetors it’s imperative that the fuel lines are identical in length from the Y-fitting to the fuel inlets.

Connect the fuel tank lines as shown in Figures 1, 2 and 3.

The proper “plumbing” of the lines is extremely important to the performance of any engine.

Figure 2

FA-300TTDP

Air out nipple

Air intake nipple

Vent line

Excess pressure outlet

Pressure adjusting valve

Figure 1

Connect this end of fuel tubing to the nipple on the muffler conncected to the right cylinder. This connection will carry the fuel residue away from your aircraft.

Breather nipple

FA-300TL

Vent line

Figure 3

FA-100T

Tank vent line

Page 8

Figure 4

FA-182TD

Aluminum stopper

Right carb spray bar

STARTING THE ENGINE

4. Be certain the mufflers are installed properly by oiling the threads and inserting the muffler gasket (79) if applicable, and that the lines are properly connected.

5. Fill the fuel tank.

6. Prime the engine:

• check to make sure the glow plugs are not connected to the heat source (glow plug clip/locking socket)

• open throttle fully

• close choke valve (92), if applicable

• rotate propeller in a counterclockwise direction 2–3 times or until fuel begins to drain from the carburetor

• open choke valve (92), if applicable

NOTE: The 90-TS is primed by inserting approximately 1–2cc of fuel into the priming nipple on the carburetor with a syringe.

NOTE: This process is not applicable for owners of the Saito FA-130 and FA-182TD. Instead, remove the aluminum stopper from the silicone tubing leading to the right cylinder/carburetor spray bar. Inject approximately 5cc of fuel into the silicone tubing. Replace the aluminum stopper. Please refer to

Figure 4.

7. Start the engine:

• close the throttle to

–

open

position

• rotate propeller clockwise until it’s against the compression stroke

• connect the heating source to the glow plugs

NOTE: It is not necessary to ignite all four glow plugs in the dual plugged versions (two glow plugs per cylinder) of the Saito engines. It’s only necessary to apply heat to the two rear plugs. The front glow plugs will ignite once the engine reaches operating temperature.

NOTE: A very common error is to remove the glow plug ignitor too early. It is suggested that the ignitor is left attached until after the engine has been run up and the high speed needle valve(s) has been properly adjusted.

Page 9

STARTING THE ENGINE

• Using either the “chicken stick” or electric starter, spin the propeller until the engine is running.

NOTE: When using an electric starter, care should be taken to be sure that the engine does not become “hydro-locked.” While the electric starter will turn the engine over,it may damage the connecting rod or other components. If the engine becomes hydro-locked, simply remove the glow plugs and turn the engine over a few times with the “chicken stick” or electric starter. The excess fuel will be forced to exit the engine via the cylinder heads.

8. Initial break-in: Do not exceed 4,000 rpm for the first

ten (10) minutes of operation. This allows all parts to mate properly with good lubrication.

NOTE: Due to the excessively “rich” mixture setting, it may be necessary to leave the heat source attached to the glow plugs.

Subsequent runs may be made while slightly leaning out the mixture with each tank full of fuel. Generally, 40 minutes is considered sufficient for normal break-in prior to the first flight.

9. After break-in:

If a test stand was used for the break-in procedure, the engine may now be mounted in the aircraft using the integral motor mount and mounting hardware supplied with the Saito engine.

NOTE: Always use the engine’s mounting spacers. Place the mounting spacer between the integral motor mount and the firewall of the aircraft.

The spacers will minimize firewall depression and serve to reinforce. Soft mounting of Saito engines is not required due to low vibration levels found in the Saito twins. The idle needle valve(s) (89) may now be refined. Please refer to the Carburetor Adjustments Section on pages 8 & 9 for information on how to do so.

The valves may be checked at this time. Refer to the Engine Maintenance Section on page 13 for information on the valve adjustment.

Figure 5

When tightening bolts, put washers between the engine mount and firewall to minimize depression on the firewall and for reinforcement.

Engine mounting spacer (washer)

Engine

Firewall

Page 10

ENGINE OPERATION

The use of a tachometer is encouraged for setting the high-speed needle valve(s) (85) prior to flight. The peak rpm should be obtained and then reduced by approximately 200–300 rpm by turning the high speed needle valve(s) counterclockwise.

Low Speed Carburetor Adjustments

The low speed, or idle needle valve(s), or airbleed screws(s) (89), is/are pre-adjusted at the factory for best performance during break-in. After break-in it may be necessary to “fine tune” the low speed adjustment using the following procedure:

1. Start the engine and let it warm

prior to attempting any adjustments.

2. Close the throttle slowly and adjust the low speed setting by rotating the needle valve(s) (89) clockwise to lean the mixture and counterclockwise to richen the mixture. The direction of rotation is reversed for the Saito FA-100T and FA-182TD. These engines are equipped with airbleed style carburetors, rotating the airbleed screw clockwise will richen the mixture. If the airbleed screw is rotated counterclockwise the mixture will become lean.

NOTE: The fuel mixture is too rich if when you open the throttle rapidly the engine emits white smoke and “stutters” or “stumbles.” Correct this by rotating the idle needle valve(s) clockwise (or airbleed screws counterclockwise)

turn at a time until the engine transitions smoothly without hesitation upon opening the throttle rapidly. The fuel mixture may be too lean when the engine stops at the lowest idle position, or if the engine stops when the throttle is rapidly opened from idle. Attempt to correct this by rotating the idle needle valve(s) counterclockwise (or airbleed screws clockwise)

turn at a time until the engine transitions smoothly without hesitation upon opening the throttle rapidly. If the situation is not rectified by counterclockwise rotations of the idle needle valve(s) (or airbleed screws clockwise), try turning the idle needle valve clockwise (or airbleed screws counterclockwise) in

turn

increments.

3. After obtaining the proper idle setting, the low rpm setting can be made through the positioning of the throttle adjustment screw if applicable. If not, adjust the idle setting via the throttle trim of your transmitter.

Page 11

ENGINE OPERATION

FA-100T/ FA-130TD/FA-182TD Dual Carburetor Adjustment

Upon completing the break-in and carburetor adjustment procedures mentioned previously, the following method should be utilized to balance the dual carburetor Saito engines:

1. Start the engine and allow it to warm up prior to attempting any adjustments.

2. Rotate both high speed needle valves clockwise an equal amount until the engine reaches the peak rpm.

3. Back off both high speed needles (rotate counterclockwise) equally until the rpm drops by 300.

4. Rotate the high speed needle valve clockwise on the right cylinder to peak the engine. Next, rotate the needle valve counterclockwise until an rpm drop of 300 is noticed.

Repeat Step 4 for the left cylinder.

The cylinders of your Saito twin are now correctly balanced.

FA-300TTDP Dual Carburetor/Fuel Pump Adjustment

Prior to starting the FA-300TTDP it’s imperative that the fuel pump connections are properly installed. Please refer to Figure 2 on page 5.

High Speed Needle Valve Adjustments

1. Start the engine and allow it to warm up prior to attempting any adjustment.

Advance the engine to full throttle.

3. Rotate the high speed needle valve of the right cylinder clockwise (leaning the mixture) until the rpms begin to sag or drop slightly. Then richen the mixture for the right cylinder by 4 or 5 clicks, not turns, of the high speed needle valve. Rotate the high speed needle valve of the left cylinder clockwise (leaning the mixture) until the rpms begin to sag or drop slightly. Then richen the mixture for the left cylinder by 4 or 5 clicks, not turns, of the high speed needle valve.

Again, lean the right cylinder by turning the high speed needle valve clockwise until the rpms begin to drop. This time, however, richen the

Page 12

ENGINE OPERATION

fuel mixture by rotating the high speed needle valve counterclockwise 3 clicks. Lean the left cylinder by turning the high speed needle valve clockwise until the rpms begin to drop. This time, however, richen the fuel mixture by rotating the high speed needle valve counterclockwise 3 clicks. The high speed needle valve adjustments are now completed.

Idle Needle Valve Adjustment

1. Lower the throttle of the Saito FA300TTDP to the lowest possible idle while retaining its reliability. Make sure the carburetor linkage assembly is secured to prevent movement of the throttle levers.

2. Lean the right cylinder low speed mixture screw (turning the screw clockwise) until the rpms drop off slightly. Richen the low speed mixture by turning the idle screw

turn counterclockwise. Lean the left cylinder low speed mixture screw (turning the screw clockwise) until the rpms drop off slightly. Richen the low speed mixture by turning the idle screw

turn counterclockwise.

Fuel Pump Adjustment

See Figure 6.

1. Begin with the pressure adjusting

valve open 2

turns.

2. Start the engine and allow it to warm up prior to attempting any adjustments.

3. Advance the engine to full throttle.

4. Rotate the pressure adjusting valve in

turn increments—first clockwise

turn (rich) then rotate

counterclockwise

turn (lean) until the best rpm is achieved. It’s important to note that the pump system has a definite response lag. This lag is approximately 2–5 seconds. With each

turn change of the pressure adjusting valve, allow the engine rpm enough time to stabilize. This will prevent “chasing” of the correct setting.

FA-300TTDP

Air out nipple

Air intake nipple

Vent line

Excess pressure outlet

Pressure adjusting valve

Figure 6

Page 13

ENGINE OPERATION

Normal Engine Operation

If break in was accomplished on a test bench your engine may be mounted to the aircraft and flown. The initial flight should be performed with the engine adjusted for a rich fuel mixture.

1. Your Saito engine should be securely mounted to the aircraft using the motor mount and hardware kit provided. Soft mounting of the Saito twins is not necessary due to the extremely low vibration level of these engines. Please refer to Step 9 in the Starting The Engine section for the proper mounting procedure.

2. General operating procedures which ensure long engine life are:

Do not operate the engine with a “lean” mixture setting.

When installing the mufflers, oil both the manifold threads and the engine cylinder threads. Secure the mufflers to the airframe using the muffler brackets supplied.

NOTE: The muffler brackets are not supplied with the FA-130TD or FA-182TD.

Regularly check all screws and nuts on both the engine and muffler.

After 1–2 hours of operation, valve adjustment may be necessary. Adjust the valves as shown in the Engine Maintenance Section following.

For engines equipped with a breather nipple, it’s recommended that a length of silicone fuel tubing be attached to this crankcase breather nipple (19). This is used to route away expelled oil from the engine compartment.

Engine Maintenance

DO NOT DISMANTLE THE ENGINE UNLESS ABSOLUTELY NECESSARY.

If it becomes necessary to dismantle your Saito engine, the following procedure should be followed:

It’s important to maintain identif ication of the “left” and “right” cylinder parts when dismantling and reassembling the engine. Looking forward from the rear of the engine with the engine upright, the cylinder on the right side is indeed the right cylinder. Therefore,the cylinder to the left is, of course, the left cylinder.

1. Cylinder and cam housing screws should be loosened in a criss-cross pattern.

Page 14

ENGINE MAINTENANCE

2. Cam Gear Alignment–Refer to the specific section below pertaining to your Saito engine.

FA-60T/90TS a. The crankshaft alignment mark

should line up with the crankcase mark when the crankshaft is at the top dead center. Refer to Figure 7.

b. Locate the cam gear reference mark and align it with the crankcase mark. See Figure 8.

c. Be sure there is a spacer on the counter gear shaft. Next, insert the counter gear onto the shaft, followed by another spacer. During this step

it’s important that neither the crankshaft nor the cam gear are moved from their alignment marks. Refer to Figure 9.

FA-100T/FA-130/FA-182TD a. Viewing the engine from the rear

and looking forward, adjust the cam timing beginning with the right cylinder.

b. Position the cam gear timing mark (dot) at the 9 o’clock position (directly into the crankcase) with the right piston at top dead center. Secure the right cam gear housing in place.

c. Rotate the crankshaft counterclockwise 180 degrees, placing the left piston at top dead center. Refer to

Figure 10.

Crankshaft alignment mark

Crankcase mark

Figure 7

Figure 8

Figure 9

Finished assembly

Crankcase alignment mark

NOTE: Crankshaft alignment mark and cam gear reference mark are aligned with their respective crankcase marks. This is extremely important.

Camgear reference mark

Page 15

ENGINE MAINTENANCE

Position the left cam gear timing mark (etched line) at the 3 o’clock position (directly into the crankcase) and secure the left cam gear housing. See Figure 11.

NOTE:When tightening the cam gear housing bolts, apply a drop of oil to each bolt to prevent thread damage. Also, tighten the bolts in a criss-cross pattern to avoid warping.

FA-300TL/FA-300TTDP e. Follow the same procedure as

described for the FA-100T/FA130

TD/ F A-

182TD

. However, instead of rotating the crankshaft 180 degrees, rotate the crankshaft 360 degrees to place the left piston at the top dead center.

3. Reassemble the piston, rod, rocker arm, pins, pushrod, tappet, etc. in their original positions. Engine parts are mated after running the engine, and they must be reassembled as close as possible to their original position.

4. Assemble the engine reversing the criss-cross pattern used in the disassembly. Prior to tightening each of the screws, apply a drop of oil to prevent thread damage.

5. Adjust the valves to a clearance of .03mm–.10 mm (.002"–.004") using the supplied gauge. The valves must be adjusted with the engine cold due to thermal expansion.

NOTE: Valves must be in the closed position.

Carburetor Maintenance

Should you experience difficulty with the carburetor of your engine:

Figure 10

1st (Right cylinder) Proper crankshaft position

Cam gear

Bench mark

Pinion gear

Figure 11

2nd (Left cylinder)

Cam gear

Bench mark Pinion gear

Revolution

T appet Adjustment

Adjust between

0.03 - 0.10 mm (.002" - .004") Gauge

(0.1 mm Max.)

Figure 12

Tappet adjustment

Page 16

CARBURETOR MAINTENANCE

1. Remove the high speed needle(s) (85) and flush out the spray bar with clean fuel. Replace the high speed needle(s) and follow the instructions in the carburetor adjustment section.

2. Always use a high-quality 4-cycle glow plug. The Hangar 9/McCoy MC-4C is highly recommended.

Tips For Extended Engine Life

T o add longer life to your Saito engine, we recommend the following:

1. Use a fuel containing 20% lubricants.

2. Use the recommended glow plugs.

3. Use the proper propeller size and

balance the propeller prior to use.

4. Use a tachometer for precise engine adjustments.

5. Use an “after-run” oil when you’re finished flying for the day.

6. For long-term storage, make sure there is no fuel left in the tank and the engine. Remove the glow plug and apply several drops of high-quality oil (i.e., Marvel Air Tool Oil) to the top of the engine, down the pushrod tubes, and through the crankcase pressure vent if applicable. Rotate the crankshaft several times. Store the engine in the box or on the airplane with the nose down in order to keep oil in the bearings.

Troubleshooting

Generally speaking, there are very few things that will keep today’s modern glow engines from starting. To that end, make sure you’re using good quality “fresh” fuel, there are good glow plugs installed, and the starting battery is charged and in good condition. Should the engine fail to start after these items are verified, refer to the chart on the following page.

Page 17

TROUBLESHOOTING

SYMPTOM CAUSE CORRECTIVE ACTION

Engine fails to Low voltage on Replace/recharge the fire starting battery starting battery

Bad glow plug(s) Inspect/replace bad glow plug(s) Insufficient priming Repeat priming procedure “Flooded” due to Disconnect battery, remove

excessive priming glow plugs,and rotate propeller

several times to“clear” cylinder

Engine fires but Over primed Disconnect battery and rotate does not run propeller several times to

“clear” cylinder

Incorrect glow Remove plugs and verify plugs proper heat range

Engine starts but Mixture too rich

Close high speed needle valve(s)

slows down and 1/2 turn and start again. Repeat then stops

until engine is running smoothly.

Engine starts, Mixture too lean

Open high speed needle valve(s)

speeds up, and 1/2 turn and start again. Repeat then quits

until engine is running smoothly.

Engine quits Mixture too rich

Close high speed needle valve(s)

when starter 1/2 turn and restart battery is removed Incorrect glow plugs Change glow plugs

Incorrect or bad fuel Change fuel

Rough idle Plug Change plug type

In the event that none of the above procedures results in the engine running properly, contact our service department for suggestions at:

Horizon Service Center 4105 Fieldstone Road Champaign, Illinois 61822 217-355-9511 (Mon–Fri 8:00–5:00 CST)

Page 18

Twin Cylinder Cross Reference Chart

TROUBLESHOOTING

PART P LL AA S DD Z W

FA-60T FA-90TS FA-100T FA-130TD FA-182TD FA-300TL FA-300TTDP

01 Cylinder, Left 60T01 90TS01 100T01 130TD01A 182TD01 300T01 300TTDP01A 02 Cylinder,Right 60T02 90TS02 100T02 130TD02A 182TD02 300T02 300TTDP02A 06 Piston 60T06 90TS06 5006 6506 91506 300T06A 300T06A 07 Piston Pin 60T07 4507A 5007 6507 91507 12007 12007 08 Piston Pin Retainer (6 Pc) 4008 5008 4008 6508 6508 300T08 300T08 09 Piston Ring 60T09 45S09 5009 6509 91509 300T09A 300T09A 10 Connecting Rod 60T10 90TS10 90T10 130T10 182TD10 270T10C 270T10C 11 Linked Connecting Rod — — 90T11 130T11 182TD11 — — 13 Connecting Rod Screw 60T13 90TS13 — — — 270T13 270T13 14 Cylinder Screw Set 60T14 60T14 4014 6514 6514 12014 12014 15 Crankcase 60T15 90TS15 100T15 130T15 182TD15 270T15A 270T15A 17 Rear Cover (A) 60T17 90TS17 — 130T17 — 270T17A 270T17A 18 Rear Cover (B) 60T18 60T18 — — — — — 19 Breather Nipple 60T19 6519 4019 4019 6519 4019 — 20 Front Ball Bearing 60T20 5020A 65GK20 8020 1827D20 270T20 270T20 21 Main Ball Bearing 60T21 60T21 — — — 270T21 270T21 22 Rear Ball Bearing 60T22 60T22 4022 6522A 182TD22 270T22 270T22 23 Crankshaft 60T23 90TS23 100T23 130T23 182TD23 270T23B 270T23B 24 Pinion-Crankshaft — — 4024 — — — — 25 Pinion Gear Pin — — 4025 — — — — 26 Collar, Crankshaft — — 90T26 — — — — 27

Tapered Collet & Drive Flange

60T27 60T27 6527 130T27A 12507 270T27B 270T27B 28 Prop Washer & Nut 5028 5628 5028 12028A 12028A 270T28A 270T28A 29 Prop Nut, Spinner — — — 12029 — — 30

Prop Nut, Electric Starter

— 5030A 5030 — — — — 31 Crankcase Screw Set 60T31 60T31 90T31 130T31 182TD31 300T31 270TTDP31 32 Engine Gasket Set 60T32 60T32 90T32 130T32 182TD32 300TL32A 300TTDP32 33 Cam Gear Housing — — 5033A 130T33A 182TD33 300T33 300T33 34 Cam Gear, Left — — 130T34 130T34 182TD34 300T34 300T34 35 Cam Gear, Right 60T35 60T35 5035 5035 6535A 120S35 120S35 36 Cam Gear Shaft — — 4036 4036 182TD36 4036 4036 37 Teﬂon/Steel Washer Set 60T37 60T37 90T37A 90T37A 182TD37 120S37 120S37 38 Tappet (2 Pc) 5038 5038 5038 5038 5038 120S38 120S38 39 Pushrod (2 Pc) 60T39 90TS39 5039 6539 91539 300T39 300T39 40

Pushrod Cover Rubber Seal (Pr)

60T40 90TS40 5040 6540 60T40 300T40 300T40 41 Rocker Arm (Pr) 60T41 60T41 4041 4041 4041 12041 12041 42

Rocker Arm Screw Nut (2 Sets)

4042 5042 4042 4042 4042 300T42 300T42 43 Rocker Arm Pin (2 Pc) 60T43 60T43 4043 4043 4043 12043 12043 44

Rocker Arm Bracket, Left

— — — — — 12044 12044 45 Rocker Arm Bracket, Right — — — — — 12045 12045 46 Valve-In/Out (Pr) 60T46 90TS46 5046 6546 91546 120S46 120S46 47

Valve Spring, Keeper, Retainer (2 Sets)

5047 5047 5047 6547 6547 300T47 300T47 48 Valve Retainer (4 Pc) 5048 5048 5048 5048 5048 120S48 120S48 49 Rocker Arm Cover (Pr) 60T49 60T49 40S49 4049 40S49 120S49 120S49 52 Counter Gear 325R552 325R552 — — — — — 53 Counter Gear Shaft 60T53 60T53 — — — — —

Page 19

PARTS LIST

PART P LL AA S DD Z W

FA-60T FA-90TS FA-100T FA-130TD FA-182TD FA-300TL FA-300TTDP

64 Air Pump Assembly — — 130T64C 130T64C — — — 65 Air Pump Housing — — 100T65B 130T65B — — — 66

Diaphragm & Check Valve Rubber Set

— — 130T66B 130T66B — — — 67

Diaphragm, Pushrod, Return Spring

— — 130T67A 130T67A — — — 68 Check Valve-In/Out (Pr) — — 130T68A 130T68A 182TD69 — 130T68A 69 Intake Manifold, Left 60T69 90TS69 90T69 130T69 182TD70 300TL69A — 70 Intake Manifold, Right 60T70 90TS70 90T70 — 182TD71 300TL70B — 71 Intake Manifold Nut 60T71 100T71 90T71 — — 300T71 — 72 Intake Manifold w/Primer — — — 130T72A 182TD73 — — 73 Muffler, Left 60T73B 90TS73 100T73 130T73 182TD74 270T73B 270TTDP73B 74 Muffler, Right 60T74B 90TS74 100T74 130T74 6579 270T74B 270TTDP74B 79 Muffler Gasket (5 Pc) 4079 — 4079 130T79 6580 12079 12079 80 Muffler Nut (2 Pc) 4080 60T80 4080 325R580 182TD81 12080 12080 81 Priming Harness — — — 130T81A 182TD821 — — 821

Carburetor-Complete, Left

60T821 90TS821 100T821 130T821 — 300TL821B 270TDP821A 822

Carburetor-Complete, Right

— — — — 182TD831 — 270TDP822A 831

Carburetor Body Assembly, Left

60T831 90TS831 90T831 130T831A — 300TL831B 270TDP831A 832

Carburetor Body Assembly, Right

— — — — — — 270TDP832A 84 Spray Bar Assembly 130T84 60T84 90T84 130T84 12085 120S84 120S84 85

High Speed Needle Valve

130T85 90TS85 90T85 130T85 90T86 12085 12085 86

High Speed Needle Valve Extension

4086 5086 90T86 90T86 182TD87 4086 90T86 87 Throttle Barrel Assembly 60T87 90TS87 100T87 130T87A 182TD88 300TL87 270TTDP87 88 Throttle Lever 60T88 325R588 90T88 130T88 182TD88 300TL88A 270TTDP88 89 Idle Needle Valve 130T89 60T89 90T89 130T89 182TD90 120S89 120S89 90 Carburetor Screw & Spring Set 60T90 60T90 90T90 130T90 182TD91 300TL90A 270TDP90A 91 Carburetor Gasket Set 60T91 90TS91 90T91 130T91 — 300TL91 270TTDP91 92

Choke Valve Assembly

60T92 — 90T92 — 182TD93 120S92 270TTDP92 93 Intake Velocity Stack — — — — 90T94 12093 12093 94 Glow Plug Harness 90T94 — 90T94 90T94 — 270T94 270T94 95 Engine Mount 60T95 60T95 — 130T95A 182TD96 325R595A 325R595A 96 Tool Set 60T96 60T96 90T96A 130T96A 270799A 270T96AB 270TTDP96 99 Muffler Bracket 60T99 60T99 60T99 — — 270T99A 270T99A 101

Twin Carburetor Control Assembly

— — — — — — 270TTDP101 102 Fuel Pump System — — — — — — 120SDP102 103

Carburetor Fitting Flange w/Screw

— — — — — — 270TTDP103 104 Cam Gear Bearing, Rear 60T104 60T104 — — — — — 105 Cam Gear Bearing, Front 60T105 60T105 — — — — — 106 Cam Gear Bearing Shield 60T106 60T106 — — — — — 107 Carburetor Bracket — — — — — 300TL107 — 109 F-1 Fuel Filler 40109 — 40109 40109 — 40109 40109 110 Anti-Loosening Prop Nut — 56-110 — — — 270T110 270T110 116 M3 Nut for Spinner — — — — — — — 117 M4 Nut for Spinner 65117 — 65117 65117 — — — 118 M5 Nut for Spinner 65118 — 65118 65118 — — — 119

Rear Cover w/Integrated Motor Mount

— — 100T119 — 182TD119 — — 121 Crank Pin Spacer, T eﬂon — — 100T121 — — — — MAN Saito Twin Cylinder Manual SAIMAN2 SAIMAN2 SAIMAN2 SAIMAN2 SAIMAN2 SAIMAN2 SAIMAN2

Twin Cylinder Cross Reference Chart

Page 20

PARTS LIST

You will note a letter (A, B, C, etc.) stamped on the top of the motor mount. This letter identifies the production version of your engine. Should you ever need to order a part or have a question pertaining to your engine, specify this letter along with the engine type. This will allow ease in identifying your engine.

Saito Twin Cylinder Prop Chart

NOTE: All recommendations are based on engines using APC props, Power Master 15% 2-stroke fuel, and McCoy MC-4C glow plugs.

ENGINE SPORT SCALE

FA-60T 10x6, 10x7 11x5, 11x6, 12x4

2000–10,500 rpm 11x5, 11x6, 12x5 12x5

FA-90TS

2,000–10,000 rpm 12x8, 13x6, 13x8 13x8, 14x6

FA-100T/130TD 12x8, 13x6, 13x8 13x8, 14x6, 14x8 2000–10,500 rpm 14x6 15x4, 15x5

FA-182TD 14x12, 14x10, 15x10 16x6, 16x8, 16x10 2000–10,500 rpm 15x8, 16x6, 16x8 18x6

FA-300TL/300TTDP 18x10, 20x8, 20x10, 20x8, 20x10, 22x8 2000–6000 rpm 20x12, 22x8, 22x10 22x10, 24x8

NOTE: Observe operating rpm ranges as excessive rpm can result in damage to the engine.

Propeller Selection

Below you will find a propeller selection chart. This chart will enable you to select the best propeller for initial set-up of your Saito engine.

Remember, it is imperative to balance each propeller prior to installation onto your Saito engine. Failure to do so may cause unwanted vibration in your aircraft.

Page 21

PROPELLER SELECTION

SPECIFICATIONS

Items Disp Bore Stroke Weight K Cylinder HP

(cc) (mm) (mm) (g) (ISO)

FA-60 Twin Cylinder 10.0 20.0 16.0 750 M7x1 5ccx2 ABC 0.9 FA-90TS Twin Cylinder 14-98 22.4 19.0 723 M7

x1 7.4x2AAC 1.4

FA-100 Twin Cylinder

16.4 23.4 19.0 820 M7x1 8.2ccx2 ABC 1.6 FA-130 Twin Cylinder/Dual Plugs 21.2 24.8 22.0 1,300 M8x1.25 10.6ccx2 ABC 1.9 FA-182 Twin Cylinder/Dual Plugs/Dual Carb

29.98 28.2 24.0 1,040 M8x1.25 14.99ccx2 AAC 2.8 FA-300 Twin Cylinder 50.0 34.0 28.0 1,750 M10x1.25 25ccx2 AAC 4.7 FA-300 Twin Cylinder/Dual Plugs/Fuel Pump/Dual Carb

50.0 34.0 28.0 1,800 M10x1.25 25ccx2 AAC 4.8

OUTSIDE DIMENSIONS (mm)

Items A B1 B2 C D E F

FA-60 Twin Cylinder 61 10 43 125 160 64 50 FA-90TS Twin Cylinder 61 10 42 121 170 64 52 FA-100 Twin Cylinder

50 35 35 100 169 80 63 FA-130 Twin Cylinder/Dual Plugs 78 30 43 131 188 82 68 FA-182 Twin Cylinder/Dual Plugs/Dual Carb

70 28 28 133 195 81 73 FA-300 Twin Cylinder 112 30 49 175 233 92 83 FA-300 Twin Cylinder/Dual Plugs/Fuel Pump/Dual Carb

112 30 49 175 233 102 83

Page 22

90A

105

106

104

FA-60T

ENGINE SPECS

Page 23

PARTS LIST

FA-90TS

Page 24

PARTS LIST

119

33A

24 19

37A

65B

64C

66B

68A

FA-100T

Air Pump Assembly

Page 25

PARTS LIST

119

FA-182TD

Page 26

107

83A

93A

92A

09A

10B

06A

28B

27A110

95B

91A 32A

69A

91A 32A

70B

74B

73B

99A

32 49 14

4337

35 32

82A

87A

101

102

103

FA-300TL

PARTS LIST

FA-300TTDP

Twin Carburetor Control

Fuel Pump System

Page 27

PARTS LIST

Consumer Warranty and Repair Policy

1. Ship your engine, freight prepaid,

in its original box packed inside a sturdy shipping container, to:

Horizon Service Center Attn: Saito Service 4105 Fieldstone Road Champaign, IL 61822 Phone: (217) 355-9511

Include complete name and address information inside the carton, as well as clearly writing it on the outer label/return address area.

2. Include a note containing a brief

summary of the difficulty experienced and include the following information:

• Nitro content and brand of fuel

• Propeller size and brand used

• Type of glow plug used

• Type of engine mount

• Approximately how much running time the engine had before experiencing the difficulty

Date your correspondence and be sure your name and address appear on this enclosure. Also, include a phone number where you can be reached during the business day.

If your engine needs repair, please do the following:

Saito engines are guaranteed against workmanship and manufacturing defects for a period of 3 years from the original date of purchase. This warranty is limited to the original purchaser of the engine and is not transferable. Warranty repairs will

not cover:

• Normal engine wear

• Damage due to insufficient maintenance

• Damage related to overrevving of engine due to small prop size or unreasonable use

• Rusted bearings

• Crash damage

• Damage due to use of improper fuel and/or glow plug

• Damage due to lean runs such as rusted bearings, seized connecting rod or piston, etc.

• Damage caused by foreign objects (dirt or broken glow plug filaments)

• Damage caused by unreasonable mounting or running conditions (dust, insufficient cooling, improper mounting, improper propeller size or lack of balancing, etc.)

•

Damage due to improper disassembly

• Modifications of any kind

Page 28

3. Warranty Repairs

To receive warranty service you must include your original dated sales receipt to verify your proofof-purchase date. Providing that warranty conditions have been met, your engine will be repaired without charge.

4. Non-Warranty Repairs

Should your repair cost exceed 50% of the retail purchase cost, you will be provided with an estimate advising you of your options. Any return freight for non-warranty repairs will be billed to the consumer.

5. Please advise us of the payment

method you prefer to use. Please specify VISA or MasterCard, or we can return C.O.D. cash only. If you prefer to use a credit card, include your card number and expiration date.

The consumer warranty registration card in this manual must be completely filled out and mailed to:

Horizon Service Center Attn: Saito Warranty 4105 Fieldstone Road Champaign, IL 61822

WARRANTY& REPAIR

Page 29

Page 30

Consumer Warranty Registration

Fill in and mail this form along with your dated sales receipt (send copy, keep original for your files) within

10 days of purchase to: Horizon Service Center

Attn: Saito Warranty Dept.

4105 Fieldstone Road

Champaign, IL 61822

Engine T ype ____________________________________________________

Date of Purchase__________________________________________________

Owner’s Name __________________________________________________

Street Address ____________________________________________________

City/State/Zip ____________________________________________________

Daytime Phone Number ____________________________________________

Purchased From:

Dealer’s Name____________________________________________________

Street Address ____________________________________________________

City/State/Zip ____________________________________________________

✄

Please cut on dotted line.